Knockdown modular mattress

ABSTRACT

The field of the present invention pertains to knockdown mattresses. More particularly, the present invention relates to mattresses that can be assembled and disassembled by the end user. The present invention when assembled or reassembled presents a visual impression to the end user looks like a conventional “factory assembled” mattress. The invention further provides for a modular mattress assembly kit that can be shipped by express delivery services while taking up far less volume than a conventional mattress.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The field of the present invention pertains to mattresses. More particularly, the present invention relates to knockdown mattresses that can be assembled and disassembled by the end user. The present invention when assembled or reassembled presents a visual impression to the end user looks like a conventional “factory assembled” mattress. The invention further provides for a modular mattress assembly kit that can be shipped by express delivery services while taking up far less volume than a conventional mattress.

(2) Description of the Related Art, Including Information Disclosed Under 37 CFR 1.97 & 1.98

The prior art has looked at forms of modular mattress construction in the past. However, the prior art has failed to disclose a combination of elements that can not only be assembled and reassembled by an end user, but also can provide the desired quality look of a conventional factory assembled mattress.

For example, U.S. Pat. No. 3,950,800 to Garshfield discloses a modular mattress structure having insulators, stuffing pad, and a cover having an inner flange that holds the components in place.

A customized modular mattress bedding is also shown in U.S. Pat. No. 5,745,940 to Roberts et alia. Layers of foam are into a support module according to the end users desire for support.

Another approach to a modular mattress having a removable liquid filled insert is seen in U.S. Pat. Nos. 6,192,538 and 6,481,033 to Fogel. At least two support modules are positioned side by side, with a depression in the top of the support module. A comfort cushion is disposed atop each module, lying in the depression. The walls of the support modules are wrapped in a non-woven material that is adhesively bonded thereto, this material providing the dimensional stability for the mattress.

None of the above systems have been accepted commercially. They all lack an acceptable finished mattress look to the end user. Furthermore, none of these systems provide for a system in which the mattress can be broken down and shipped by the end user in half the volume or less of the assembled mattress.

BRIEF SUMMARY OF THE INVENTION

The field of the present invention pertains to mattresses. More particularly, the present invention relates to mattresses that can be assembled and disassembled by the end user. The present invention, when assembled or reassembled, presents a visual impression to the end user looks like a conventional “factory assembled” mattress. The invention further provides for a modular mattress assembly kit that can be shipped by express delivery services while taking up far less volume than a conventional mattress.

The present invention comprises a modular mattress (10). As seen in FIGUREs, the combination of elements for this mattress includes the following: a peripheral support module (20), at least two mattress chambers (30), a plurality of internal support modules (40), and a mattress cover (50).

The peripheral support module has exterior lateral edges (22) and (24) extending the depth of the mattress that define the outer dimensions of the modular mattress. The peripheral support module can be comprised of a supportive and compressible foam. The dimensions of this module should extend inward a sufficient distance to enable a typical user to sit on the edge of the assembled mattress and provide support such that the mattress perimeter maintains firmer support than that support provided by the internal modular support component. Thus, edge stability of the mattress is maintained when the user is in a seated position atop the mattress. Additionally, such a combination of support permits the user to occupy the full width of the mattress when in a reclining position.

The mattress chambers (30) are openings disposed within the interior of the peripheral support module. Each chamber defines interior chamber walls (32) on the peripheral support module. Each chamber can be filled with an internal support module (40). These modules can be constructed out of various conventional mattress support structures such as spring sets, foam blocks, fluid bladders, laminated combinations, or the like. Each internal support module is sized and dimensioned to fit in a snug relationship with the interior walls (32) of its respective chamber. The snugness is defined by a combination of the degree of the stiffness of the peripheral module. Thus, the support module may displace outwardly the interior walls of the chamber.

A mattress cover (50) completely envelops the combination of the peripheral support module and the accompanying internal support modules. The cover has a top panel (52), a lateral skirt (54), a bottom panel (56), and a closure means (58). The cover is sized and dimensioned to permit the combination of the top panel, the lateral skirt, and the bottom panel to apply tension to the combination of the peripheral support module and the internal support modules within the respective chambers. The tension created by the cover, once the closure means is closed, holds the peripheral support module and the internal support modules in a relatively fixed position with respect to each other, distributes any mattress load amongst the combination of the peripheral support module and the internal support modules, and maintains the cover in a taught state throughout its panels and skirt, even without a mattress load. By “relatively fixed”, the present invention refers to the fact that the internal support module will not shift vertically or horizontally in a chafing fashion with respect to the peripheral support module either when conventional mattress loads are applied or in a resting non-loaded position.

The present invention also comprises an unassembled modular mattress kit. Using the above elements, one can have the internal support modules separate from the peripheral support module. Each internal support module is configured so as to be able to be compressed to less than half the volume in the uncompressed state. Likewise, the peripheral support module is configured so as to be able to be compressed to less than half the volume in the uncompressed state. Each internal support module can have a binding means attached that secures the support module in a compressed state for ease of handling. Likewise, the peripheral support module can have a binding means attached that secures the support module in a compressed state for ease of handling. Optionally, at least part of the cover can be attached to the peripheral support module. Such a kit enables one to ship a knock down mattress through conventional express delivery services.

The present invention also comprises a method for assembling a knockdown mattress from the above mattress kit. The steps of this method include first selecting a combination of elements as described above. Second, one decompresses the peripheral support module and the internal support modules. Then one inserts each support module into its respective chamber in the peripheral support module. One places the cover about the combination and moves the closure means into a closed position.

An object of the invention is to provide a knockdown mattress that has the look and comfort of a quality, fixed assembly mattress while having the assembly/disassembly functionality of a knockdown mattress.

A second object of the invention is to provide a knockdown mattress that can be assembled without any tools.

A third object of the invention is to provide a knockdown mattress that can be disassembled into a package that can be shipped through conventional ground delivery services, such as FedEx Ground or United Parcel Service.

A fourth object of the invention is to provide a knockdown mattress in which the modular components do not shift in use and are not detectable from the exterior.

A fifth object of the invention is to provide the ability of either designing or converting a mattress on a customized basis to satisfy individual comfort requirements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of the present invention showing the claimed elements with the top mattress cover in an open position.

FIG. 2 is a side cutaway view of a preferred embodiment of the present invention showing the claimed elements in an open position.

DETAILED DESCRIPTION OF THE INVENTION

A preferred modular mattress embodiment is shown in the FIGUREs. As seen in FIG. 1, the combination of elements for this mattress includes the following: a peripheral support module (20), at least two mattress chambers (30), a plurality of internal support modules (40), and a mattress cover (50).

The peripheral support module can be constructed in several ways. It can be molded as one piece. It can be fabricated by cutting a single piece of foam. Or it can be made by gluing pieces of foam that make up the individual lengths and widths of the peripheral support module. The peripheral support module is comprised of a supportive and compressible bedding foam such as high density polyurethane. As shown in the FIGUREs, the perimeter or bolster rails of the peripheral support module extend inward about one foot, enabling a typical user to sit on the edge of the assembled mattress. The bolster firmness is greater than that of the internal support module. Preferably, a longitudinal bolster is disposed down the middle of the mattress, separating and defining two separate mattress chambers. Preferably, the peripheral support module can have intermediate rails (26) that extend longitudinally and transversely between the outer bolster rail, thereby creating at least four mattress chambers.

Each chamber can be filled with an internal support module (40). As shown in the FIGUREs, spring sets (42) are covered in a conventional protective material. These spring sets are sized such that they snugly fit within the chambers, displacing the interior chamber walls from their original, preloaded position. Preferably, there are no voids between the internal support module and the interior chamber walls.

The mattress cover (50) comprises a fabric (including woven or knitted fabrics) that completely envelops the combination of the peripheral support module and the accompanying internal support modules. The cover is made from conventional cloth materials used on factory assembled, non-modular mattresses. The cover closure means (58) comprises a zipper along the edge of the bottom panel that can withstand the tension forces generated by the mattress cover. The mattress cover is sized such that the interior volume of the cover is less than the volume of the peripheral support module in its uncompressed state. The tension provided by the mattress cover is sufficient to provide dimensional integrity to the mattress by keeping all of the mattress elements moving together in response to load. There is no shifting of internal parts, one with respect to another due to the tension supplied by the closed cover. Fire resistance can be an important factor in a consumer selecting a bed mattress. Therefore, the mattress cover can also comprise fire-resistant material on the external surface.

In a preferred embodiment, the mattress can also comprise additional support layers atop the internal support modules. Thus, as seen in FIG. 2, one can place an upper mattress support layer (60), such as a memory foam layer, above the internal support modules and the peripheral support module.

The present invention also comprises an unassembled modular mattress kit. The kit comprises an internal support module (40) compressed along the axis of spring compression to less than half the volume in the uncompressed state. Likewise, the peripheral support module is configured compressed to less than half the volume in the uncompressed state, being folded along either its transverse axis, its longitudinal axis, or both axes. A preferred embodiment with intermediate rails would have those rails moveable so as to facilitate folding. The bottom panel of the mattress cover (56) is attached to the peripheral support module, such as by adhesive bonding. Such a kit enables one to ship the present invention through conventional express delivery services.

Finally, the present invention also comprises a method of assembling a knockdown mattress. First on selects the peripheral support module, internal support modules, and the mattress cover elements found in the mattress kit described above. One decompresses the peripheral support module and the internal support modules to an uncompressed state. Each support module is inserted into its respective chamber in the peripheral support module. If not already attached to the peripheral support module, then one places the cover about the combination. Finally, one moves the cover closure means into a closed position.

The ordinarily skilled artisan can appreciate that the present invention can incorporate any number of the preferred features described above.

All publications or unpublished patent applications mentioned herein are hereby incorporated by reference thereto.

Other embodiments of the present invention are not presented here which are obvious to those of ordinary skill in the art, now or during the term of any patent issuing from this patent specification, and thus, are within the spirit and scope of the present invention. 

1. A modular mattress comprising: a) a peripheral support module having exterior lateral edges extending the depth of the mattress that define the outer dimensions of the modular mattress, said peripheral support module being comprised of a supportive and compressible foam; b) at least two mattress chambers disposed within the interior of the peripheral support module, each chamber defining interior chamber walls on the peripheral support module; c) a plurality of internal support modules, each such internal support module being sized and dimensioned to fit in a snug relationship with the interior walls of a respective chamber, and each such internal support module being disposed within such respective chamber; and d) a cover completely enveloping the peripheral support module, said cover having a top panel, a lateral skirt, a bottom panel, and a closure means, the cover being sized and dimensioned to permit the top panel, the lateral skirt, and the bottom panel to apply tension to the combination of the peripheral support module and the internal support modules within the respective chambers such that when the closure means is in a closed position, the tension holds the peripheral support module and the internal support modules in a relatively fixed position with respect to each other, distributes any mattress load amongst the combination of the peripheral support module and the internal support modules, and maintains the cover in a taught state without a mattress load.
 2. An unassembled modular mattress kit comprising: a) a peripheral support module having exterior lateral edges extending the depth of the mattress that define the outer dimensions of the modular mattress, such peripheral support module being comprised of a supportive and compressible foam; and having at least two mattress chambers disposed within the interior of the peripheral support module, thereby defining interior chamber walls on the peripheral support module, said peripheral support module being compressed into a volume less than half the volume of the peripheral support module in an uncompressed state; b) a plurality of internal support modules, each being sized and dimensioned to fit in a snug relationship with the interior walls of a respective chamber, said internal support modules being compressed into a volume less than half the volume of the internal support modules in an uncompressed state; and c) a cover for completely enveloping the peripheral support module, said cover having a top panel, a lateral skirt, a bottom panel, and a closure means, the cover being sized and dimensioned to permit the top panel, the lateral skirt, and the bottom panel to apply tension to the combination of the peripheral support module and the internal support modules within the respective chambers such that when the closure means is in a closed position, the tension holds the peripheral support module and the internal support modules in a relatively fixed position with respect to each other, distributes any mattress load amongst the combination of the peripheral support module and the internal support modules, and maintains the cover in a taught state without a mattress load.
 3. A method of assembling a knockdown mattress comprising: a) selecting the following elements: i) a peripheral support module having exterior lateral edges extending the depth of the mattress that define the outer dimensions of the modular mattress, such peripheral support module being comprised of a supportive and compressible foam; and having at least two mattress chambers disposed within the interior of the peripheral support module, thereby defining interior chamber walls on the peripheral support module, said peripheral support module being compressed into a volume less than half the volume of the peripheral support module in an uncompressed state; ii) a plurality of internal support modules, each being sized and dimensioned to fit in a snug relationship with the interior walls of a respective chamber, said internal support modules being compressed into a volume less than half the volume of the internal support modules in an uncompressed state; and iii) a cover for completely enveloping the peripheral support module, said cover having a top panel, a lateral skirt, a bottom panel, and a closure means, the cover being sized and dimensioned to permit the top panel, the lateral skirt, and the bottom panel to apply tension to the combination of the peripheral support module and the internal support modules within the respective chambers such that when the closure means is in a closed position, the tension holds the peripheral support module and the internal support modules in a relatively fixed position with respect to each other, distributes any mattress load amongst the combination of the peripheral support module and the internal support modules, and maintains the cover in a taught state without a mattress load; b) decompressing the peripheral support module and the internal support modules to an uncompressed state; c) inserting each support module into its respective chamber in the peripheral support module; d) placing the cover about the combination; and e) moving the cover closure means into a closed position 